Summer Term 2001
2000 catalog data: Credit (3-2-4) Three lecture hours and one two-hour lab
Prerequisites: MFGG-370 Engineering Materials
The course develops skills needed to prepare a product functional specification for an n existing product, at the product, subfunctional group and individual part levels. The development and application of a function structure diagram is developed for a product. Creative concept generation tools are learned to generate alternate mechanisms to generate the functions of a product. The PUGH concept selection method is utilized to select to top ideas in each subfunctional group. New product level concepts are generated by combining the best concepts in each subfunctional group. The BDI Design for Assembly method is applied to existing products to determine a path for part consolidation. The DFA Redesign Concept Matrix is used to create novel assembly concepts.
Concepts in the course are taught through lecture and facilitated practicum.
Textbook(s): None
References: Guided lecture notes and supplemental readings are provided. The Practicum
Manual is provided all students. Selected references from the technical literature are made available for reading in the DFM/A Studio.
Coordinator(s): B. Lee Tuttle, Professor of Manufacturing Engineering
Course learning
objectives:
A student who successfully completes this course will be able to:
1. Prepare a functional specification for a product at the product, subfunctional and
individual parts level. (Program Outcomes: C, E K, O, P; MFGG PEOs: 1, 2, 3, 6, 7)
2. Develop an initial manufacturing process plan for selected parts and a first
estimate of the assembly plans for an existing product. (Program Outcomes: A, C; MFGG PEOs: 1, 2,
3, 6, 7)
3. Select reasonable materials for a primary process in a current product concept and new product
concepts. (Program Outcomes: A, C; MFGG PEOs: 1, 2, 3, 7)
4. Use creative concept generation triggers to develop evolutionary, revolutionary and radical function
concepts for products. (Program Outcome: C; MFGG PEOs: 2, 3, 7)
5. Generate reasonable criteria for concept selection and to apply the
PUGH concept selection process properly for new product concepts. (Program Outcome: C; MFGG
PEOs: 2, 3, 7)
6. Describe the role of Design for Assembly tools in DFM/A. (Program Outcomes: E, K; MFGG PEOs: 1,
2, 3, 6, 7)
7. Properly perform a Design for Assembly analysis utilizing the BDI DFA Manual method. (Program
Outcomes: E, K; MFGG PEOs: 1, 2, 3, 6, 7)
8. Transform the theoretical minimum part count metrics into linear design concepts for an assembly
utilizing the DFA Design Concept Matrix. (Program Outcomes: E, K; MFGG PEOs: 1, 2, 3, 6, 7)
9. Perform a complete DFM/A analysis and synthesis of a current product through the DFM/A term project
and the practicum exercises. (Program Outcomes: A, C, E, F, G, K, O, P; MFGG PEOs: 1, 2, 3, 5, 6, 7)
Prerequisites
by topic:
1. Principles of metal forming
2. Principles of metal casting
3. Principles of material joining processes
4. Principles of material removal processes
5. Principles of polymer processing
6. Structure, properties, and processing relationships in engineering materials
7. Heat treatment of engineering materials
8. Principles of material design for part production
9. Product disassembly
Topics covered:
1. Overview of DFM/A methodologies
2. Break even Analysis of Process and Assembly plans
3. Developing a Function Specification
4. Design for Assembly Principles
5. Boothroyd Dewhurst DFA Methodology
6. Creative Concept Generation and Selection Tools
7. PUGH concept selection method
8. Design for Material Handling ( Feeding)
9. Value Engineering Principles
Schedule: Three lecture sections of 60 minutes per week and one laboratory session of 120
minutes.
Computer usage: No computer software required.
Laboratory projects: 1. Facilitating the DFM/A term project.
2. Developing the process and assembly plan.
3. Developing the product functional specification
4. Developing the product function structure diagram
5. Employing the Assemblability Evaluation Methodology to evaluate a
product.
6. Applying Creative Concept generation and Selection tools
7. Employing the PUGH concept selection method on creative concepts.
8. Applying the Boothroyd Dewhurst Design for Assembly method to an
assembly.
9. Assembly Fault Diagnosis of a product.
Relationship to professional component: Two credits of engineering topics and two credits of engineering design
Prepared by: B. Lee Tuttle________________________ Date: __July 1, 2000__